Process of forming an electronic device including a semiconductor layer and another layer adjacent to an opening within the semiconductor layer

ABSTRACT

A process of forming an electronic device can include patterning a semiconductor layer to define an opening. After patterning the semiconductor layer, the opening can have a bottom, and the semiconductor layer can have a sidewall and a surface. The surface is spaced apart from the bottom of the opening. The sidewall can extend from the surface towards the bottom of the opening. The process can also include forming a layer over the semiconductor layer and within the opening, and removing a part of the first layer from within the opening. After removing the part of the layer, a remaining portion of the layer may lie within the opening and adjacent to the bottom and the sidewall, and the remaining portion of the layer may be spaced apart from the surface. In another aspect, the electronic device can include a field isolation region including the first layer.

RELATED APPLICATIONS

The present disclosure is relates to U.S. patent application Ser. No. 11/409,790, entitled “Process of Forming an Electronic Device Including a Layer Formed Using an Inductively Coupled Plasma” by Turner et. al. filed on Apr. 24, 2006, and U.S. patent application Ser. No. 11/409,882, entitled “Electronic Device Including a Semiconductor Layer and a Sidewall Spacer and a Process of Forming the Same” by Mora et. Al. filed on Apr. 24, 2006, all of which are assigned to the current assignee hereof and incorporated by references in their entireties.

BACKGROUND

1. Field of the Disclosure

The present disclosure relates to electronic devices and processes, and more particularly to electronic devices including semiconductor layers and layers adjacent to openings within semiconductor layers and processes of forming the same.

2. Description of the Related Art

As device performance becomes more and more demanding, semiconductor devices are now formed using semiconductor-on-insulator (“SOI”) substrates. In order to achieve a reasonably high component density, field isolation regions are typically formed between semiconductor devices. Typically, a liner layer is formed to help round the top corners of a semiconductor layer to improve gate dielectric integrity.

FIG. 1 includes an illustration of a cross-sectional view of a portion of an electronic device. The electronic device includes a substrate 12, an insulating layer 14, which can be a buried oxide, and a semiconductor layer 162 that overlies the insulating layer 14. The semiconductor layer 162 is patterned to form openings that extend through the semiconductor layer 162 to the insulating layer 14. A thermal oxidation is typically performed and grows a liner layer 164. During the formation of the liner layer 164, top corners 166 of the semiconductor layer 162 are rounded in order to improve gate dielectric integrity. However, the thermal oxidation also causes corner rounding near the bottom of the semiconductor layer 162, as seen with rounded bottom corners 168. The rounded bottom corners 168 within the semiconductor layer 162 near the insulating layer 14 are undesired. An insulating layer 18 can then be formed within the openings, with portions of the insulating layer 18 overlying the semiconductor layer 162 being removed using a conventional process. During subsequent thermal cycles, unacceptable levels of stress may be exerted by the field isolation regions (combination of the liner layer 164 and insulating layer 18) onto the semiconductor layer 162. The stress may cause electrical characteristics of the devices to change, defects, faults, fractures to form within the semiconductor layer 162, or, in extreme cases, delamination of the semiconductor layer 162 from the insulating layer 14.

Another attempt to address the bird's beak has been to form the opening extending through the semiconductor layer 162 and form a nitride layer along the bottom of the opening and not form any of the nitride layer along the sidewalls of the semiconductor layer 162 near the upper corners 166. In theory, the upper corners 166 of the semiconductor layer 162 should be exposed during a subsequent thermal oxidation, while the lower corners 168 are protected. The nitride layer can be deposited by evaporating the nitride layer, sputtering the nitride layer, or using a thermal chemical vapor technique. In practice, this technique does not work.

Sputtering is characterized by a long mean free path and no significant surface migration. Along the sidewalls, the nitride layer will be thicker at the upper corners 166 and thinner at the lower corners 168, when measured in a direction perpendicular to the sidewalls of the semiconductor layer 162. A collimator can reduce the sidewall deposition, but the deposition would still be thicker at the upper corners 166 as compared to the lower corners 168. Thus, thermal oxidation would round the upper corners 166 and the lower corners 168. Evaporation is more conformal and less directional as compared to sputtering. Therefore, a significant amount of the nitride layer will deposit along the sidewall.

A thermal chemical vapor deposition is a deposition performed without using a plasma. When forming a nitride layer using low pressure chemical vapor deposition (“LPCVD”), dichlorosilane and ammonia are typically reacted at a temperature in a range of approximately 700° C. to approximately 800° C. under vacuum and without a plasma. The deposition is characterized by a rapid surface migration and forms a substantially conformal nitride layer, which would deposit about the same thickness of nitride along the bottom of the opening as it would along the sidewalls of the semiconductor layer 162. A conformal deposition would deposit nearly equivalent thicknesses of the nitride layer along the sidewall of the semiconductor layer 162.

Therefore, a layer having a significant thickness along a bottom of an opening with no or very little sidewall coverage while protecting the lower corners 168 and allowing rounding of the upper corners 166 of the semiconductor layer 162 has not been enabled. Sputtering and evaporating a nitride layer would deposit a layer along the sidewall that would be locally thicker near the upper corners 166 as compared to the lower corners 168, and a thermal CVD process can produce a conformal layer.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited in the accompanying figures.

FIG. 1 includes an illustration of a cross-sectional view of a portion of an electronic device that includes an SOI substrate, wherein the semiconductor layer has rounded corners. (Prior Art)

FIG. 2 includes an illustration of a cross-sectional view of a portion of an electronic device workpiece after forming a mask.

FIG. 3 includes an illustration of a cross-sectional view of the workpiece of FIG. 2 after forming an opening extending through a semiconductor layer.

FIG. 4 includes an illustration of a cross-sectional view of the workpiece of FIG. 3 after forming a layer over the semiconductor layer and within the opening in accordance with an embodiment.

FIG. 5 includes an illustration of a cross-sectional view of the workpiece of FIG. 4 after forming removing part of the layer in accordance with an embodiment.

FIG. 6 includes an illustration of a cross-sectional view of the workpiece of FIG. 4 after forming a dome-shaped layer in accordance with an alternative embodiment.

FIG. 7 includes an illustration of a cross-sectional view of the workpiece of FIG. 4 after forming a remaining layer having extended portions in accordance with an alternative embodiment.

FIG. 8 includes an illustration of a cross-sectional view of the workpiece of FIG. 5 after rounding corners of the semiconductor layer near the top of the semiconductor layer.

FIG. 9 includes an illustration of a cross-sectional view of the workpiece of FIG. 8 after forming an insulating layer that fills the opening.

FIG. 10 includes an illustration of a cross-sectional view of the workpiece of FIG. 9 after forming a field isolation region is substantially completed.

FIG. 11 includes an illustration of a cross-sectional view of the workpiece of FIG. 10 after removing remaining portions of layers overlying the semiconductor layer.

FIGS. 12 and 13 include illustrations of cross-sectional views of the workpiece of FIG. 11 after forming electronic components.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention.

DETAILED DESCRIPTION

An electronic device can include a semiconductor layer. In one aspect, a process of forming the electronic device can include patterning the semiconductor layer to define an opening extending to an insulating layer, wherein the insulating layer lies between a substrate and the semiconductor layer. After patterning the semiconductor layer, the opening can have a bottom. The semiconductor layer can have a sidewall and a surface, wherein the surface is spaced apart from the insulating layer, and the sidewall extends from the surface towards the insulating layer. The process can also include forming a first layer over the substrate, wherein the first layer substantially fills the opening within the semiconductor layer. The process can further include removing a part of the first layer from within the opening. After removing the part of the first layer, a remaining portion of the first layer can lie within the opening and adjacent to the bottom and the sidewall, and the remaining portion of the first layer can be spaced apart from the surface.

In another aspect, an electronic device can include a substrate, an insulating layer, and a semiconductor layer, wherein the insulating layer lies between the substrate and the semiconductor layer. The semiconductor layer can have a sidewall and a surface, wherein the surface is spaced apart from the insulating layer, and the sidewall extends from the surface towards the insulating layer. The electronic device can also include a field isolation region overlying the insulating layer and lying adjacent to the sidewall of the semiconductor layer. The field isolation region can include a first layer that lies adjacent to the insulating layer and the sidewall, wherein the first layer is spaced apart from the surface. The first layer can have a sidewall elevation adjacent to the sidewall of the semiconductor layer and a center elevation at a center of the field isolation region. Each of the sidewall elevation and the center elevation can be measured in a direction perpendicular to the primary surface of the substrate. The sidewall elevation may be different from the center elevation.

Before addressing details of embodiments described below, some terms are defined or clarified. The term “elevation” is intended to mean the closest distance from a layer, a feature, or a surface of a layer or feature to a reference plane, such as a primary surface of a substrate.

The term “high-k” is intended to mean a dielectric constant of at least 8.0.

The term “PECVD” is intended to mean a chemical vapor deposition performed using a plasma, wherein the plasma is not significantly inductively coupled.

The term “primary surface” is intended to mean a surface of a substrate or a layer overlying the substrate or a portion of the substrate or layer from which a transistor is subsequently formed. The primary surface may be an original surface of a base material before forming any electronic components or may be a surface of the semiconductor layer that overlies the base material. For example, an exposed surface of a semiconductor layer of a semiconductor-on-insulator substrate can be a primary surface, and not the original surface of the base material.

The term “substrate” is intended to mean a base material. An example of a substrate includes a quartz plate, a monocrystalline semiconductor wafer, a semiconductor-on-insulator wafer, etc. The reference point for a substrate is the beginning point of a process sequence.

The term “workpiece” is intended to mean a substrate and, if any, one or more layers one or more structures, or any combination thereof attached to the substrate, at any particular point of a process sequence. Note that the substrate may not significantly change during a process sequence, whereas the workpiece significantly changes during the process sequence. For example, at the beginning of a process sequence, the substrate and workpiece are the same. After a layer is formed over the substrate, the substrate has not changed, but now the workpiece includes the combination of the substrate and the layer.

Group numbers corresponding to columns within the Periodic Table of the elements use the “New Notation” convention as seen in the CRC Handbook of Chemistry and Physics, 81^(st) Edition (2000).

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B is true (or present).

Additionally, for clarity purposes and to give a general sense of the scope of the embodiments described herein, the use of the “a” or “an” are employed to describe one or more articles to which “a” or “an” refers. Therefore, the description should be read to include one or at least one whenever “a” or “an” is used, and the singular also includes the plural unless it is clear that the contrary is meant otherwise.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. All publications, patent applications, patent, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.

To the extent not described herein, many details regarding specific materials, processing acts, and circuits are conventional and may be found in textbooks and other sources within the semiconductor and microelectronic arts.

FIG. 2 includes an illustration of a cross-sectional view of a portion of an electronic device workpiece 20, which includes a substrate 12, an insulating layer 14, and a semiconductor layer 22. The substrate 12 can include an electronic device substrate, such as a flat panel substrate, a semiconductor device substrate, or another conventional substrate used for forming electronic devices. The insulating layer 14 overlies the substrate 12 at a primary surface 13.

The insulating layer 14 includes an oxide, a nitride, or a combination thereof. The insulating layer 14 (usually referred to as a buried oxide layer or a BOX layer) has a thickness sufficient to substantially reduce parasitic capacitance between the substrate 12 and subsequently formed electronic devices within the semiconductor layer 22. In one embodiment, the insulating layer 14 has a thickness of at least 100 nm.

The semiconductor layer 22 can include a Group 14 element (e.g., C, Si, Ge, etc.), a III-V semiconductor, a II-VI semiconductor, or any combination thereof. In one embodiment, the semiconductor layer 22 is a substantially monocrystalline silicon or silicon germanium layer. The thickness of the semiconductor layer 22 is in a range of approximately 10 to approximately 200 nm. The combination of the substrate 12, insulating layer 14, and semiconductor layer 22 may be obtained from a commercially available source or the insulating layer 14 and semiconductor layer 22 can be formed from or over the substrate 12 using a conventional or proprietary processing sequence.

A pad layer 24 and an oxidation-resistant layer 26 are formed over the semiconductor layer 22, as illustrated in FIG. 2. In one embodiment, the pad layer 24 includes an oxide (e.g., silicon dioxide, silicon oxynitride, etc.) that is thermally grown from or deposited over the semiconductor layer 22, and the oxidation-resistant layer 26 includes a nitride (e.g., silicon nitride, silicon-rich silicon nitride, etc.) that is deposited over the pad layer 24. In one non-limiting embodiment, the pad layer 24 can have a thickness in a range of approximately 2 to approximately 40 nm, and the oxidation-resistant layer 26 can have a thickness in a range of approximately 10 to approximately 200 nm.

A mask 28 is formed over the pad layer 24 and the oxidation-resistant layer 26 using a conventional or proprietary lithographic technique to define an opening 29. In one embodiment, the mask 28 includes a resist material, such as photoresist or deep ultraviolet resist.

As illustrated in FIG. 3, the oxidation-resistant layer 26, the pad layer 24, and the semiconductor layer 22 are patterned to form an opening 32 that extends through those layers to expose the insulating layer 14 along a bottom of the opening 32. The semiconductor layer 22 includes surface 36 that is spaced apart from the insulating layer 14. After forming the opening 32, the semiconductor layer 22 includes sidewalls 34 lying along the opening 32 and extending from the surfaces 36 towards the insulating layer 14. In one embodiment, the openings in the oxidation-resistant layer 26 and the pad layer 24 and the sidewalls 34 of the opening 32 are substantially coterminous with one another. The sidewalls 34 can be substantially vertical or may include a slight taper (i.e., slightly off vertical).

In one embodiment, the oxidation-resistant layer 26 includes silicon nitride, the pad layer 24 includes silicon dioxide, and the semiconductor layer 22 includes silicon or silicon germanium. The opening 32 can be formed by dry etching the layers. Different etch chemistries can be used during the etch. The oxidation-resistant layer 26 can be etched using an etch chemistry that is tailored for silicon nitride and has good selectivity to oxide. The pad layer 24 can be etched using an etch chemistry that is tailored for silicon dioxide and has good selectivity to silicon or silicon germanium. The semiconductor layer 22 can be etched using an etch chemistry that tailored to silicon or silicon germanium. The same etch chemistries can be used for combinations of some of the layers. For example, the same etch chemistry may be used for the oxidation-resistant layer 26 and pad layer 24. Such etch chemistry may have good selectivity to silicon or silicon germanium. Alternatively, the same etch chemistry may be used for the pad layer 24 and the semiconductor layer 22. Still other etch chemistries can be used, particularly if the composition of the oxidation-resistant layer 26, the pad layer 24, the semiconductor layer 22, or any combination thereof would be different from those previously described. After reading this specification, skilled artisans will be able to select etch chemistries that meet their needs or desires. Each of etching of the oxidation-resistant layer 26, the pad layer 24, and the semiconductor layer 22 may be performed as a timed etch or using endpoint detection with an optional timed overetch.

After the opening 32 has been formed, the mask 28 can be removed using a conventional or proprietary ashing technique. In an alternative embodiment, the mask 28 can be removed after patterning the oxidation-resistant layer 26, after patterning the pad layer 24, or after forming the opening 32. In one embodiment, the oxidation-resistant layer 26 or combination of the oxidation-resistant layer 26 and the pad layer 24 can act as a hard mask while etching the opening 32 into the semiconductor layer 22.

A layer 42 can be formed over the substrate 12. The layer 42 may substantially fill the opening 32. During a subsequent oxidation, a remaining portion of the layer 42 is to slow or substantially prevent oxidation of the semiconductor layer 22 near the insulating layer 14. Thus, the material for the layer 42 can include a nitride, an oxide, an oxynitride, silicon, germanium, another suitable material used in semiconductor devices and capable of withstanding a processing temperature of at least 1000° C., or any combination thereof. The thickness of the layer 42, as formed, may be as least as thick as the thickness of the semiconductor layer 22. In one embodiment, a nitride layer can be used, and in a particular embodiment, silicon nitride can be used.

In one embodiment, the layer 42 may be formed by a deposition technique. In one embodiment, the deposition can be performed as a PECVD deposition. The PECVD deposition can deposit the material substantially conformally, i.e., at about the same thickness along all exposed surfaces of the workpiece. In another embodiment (not illustrated), the layer 42 may be non-conformally deposited using an inductively coupled plasma, such as a high-density plasma (“HDP”). For a non-conformally deposition, the layer 42 would be thicker along substantially horizontal surfaces, as compared to substantially vertical surfaces. Regardless of deposition technique, the layer 42 lies along the bottom of the opening 32 and along the sidewalls 34 of the opening 32.

An etch is performed to remove part of the layer 42. The etch may be performed as a substantially isotropic etch, using a wet chemical etchant or a dry etchant. The etching species can depend on the material within the layer 42. In one embodiment, the layer 42 includes silicon nitride, and a wet chemical etchant can include H₃PO₄. In another embodiment, the layer 42 includes silicon dioxide, and a wet chemical etchant can include HF, and in still another embodiment, the layer 42 includes amorphous or polycrystalline silicon, and a wet chemical etchant can include a base, such as (CH₃)₄NOH. In a further embodiment, a dry etch can be performed using a conventional or proprietary downstream plasma with a conventional dry etchant tailored for the material within the layer 42.

In one embodiment, the part of the layer 42 along the upper portions of the sidewalls 34 is removed, and the remaining portion 52 lies along the bottom of the opening 32 and adjacent to the insulating layer 14 and the lower portions of the sidewalls 34. After the etch is completed, the remaining portion 52 may fill approximately 20% to 80% of the opening 32 or the opening within the semiconductor layer 22. An exposed surface of the remaining portion 52 lies at an elevation significantly lower than the surface 36. The remaining portion 52 may have an exposed surface that is substantially flat.

In one particular embodiment, the layer 42 can include a PECVD deposited silicon nitride layer, and the etch may be performed using H₃PO₄ at a temperature in a range of approximately 40° C. to approximately 200° C., and in a more particular embodiment, in a range of approximately 120° C. to approximately 160° C. The etch may be performed in a partial drain refill tank. By using the partial drain refill tank, etching characteristics may be more uniform between different lots of workpieces. In another embodiment, the partial drain refill tank is not used, but a static tank (e.g., no recirculation loop) may be used.

In another particular embodiment, the etch rate of the layer 42 within the opening 32 may be locally higher near the sidewalls 34, as compared to the center of the opening 32. In this embodiment illustrated in FIG. 6, the remaining portion 62 is thicker at a center of the opening (illustrated as dimension 66) compared to a location closer to the sidewall (illustrated as dimension 68) and has a dome shape as seen from the cross-sectional view. A highest point of the exposed surface of the remaining portion 62 lies at an elevation significantly lower than the surface 36.

In a more particular, non-limiting embodiment, the semiconductor layer 22 can have a thickness of approximately 70 nm, the width of the opening 32 can be approximately 140 nm or less, and the layer 42 can be deposited using PECVD to a thickness of approximately 70 nm. A five minute H₃PO₄ etch with an etch rate of approximately 13 to approximately 16 nm/minute can be used and remove the portion of the layer 42 outside the opening and leave the remaining portion 62 with a thickness of approximately 20 to approximately 50 nm thick at the center of the opening 32, and a thickness of approximately 5 to approximately 15 nm near the sidewalls 34 of the semiconductor layer 22.

In other embodiments, the semiconductor layer 22 may be thicker or thinner, and therefore, the layer 42 may be likewise thicker or thinner. The etch time, the etch rate, or any combination thereof can be adjusted to account for the actual thickness can composition used for the layer 42. For example, the etch rate of undensified HDP nitride may be approximately ten times higher than the etch rate of PECVD nitride. After reading this specification, skilled artisans will understand how to achieve any of the remaining portions as described herein.

In still another particular embodiment, a remaining portion 72 can include extended portions 74 extends above another part of the remaining portion 72 that lies at a center of the opening 32. As seen from a cross-sectional view, the extended portions 74 can have a variety of shapes including parabolic (illustrated in FIG. 7), triangular (not illustrated), rectangular (not illustrated), or the like. The remaining portion 72 can be achieved by using an etch that is more anisotropic (i.e., more directionally oriented) as compared to the etches used in forming the remaining portion 52 or the remaining portion 62. The extended portions 74 have a sidewall elevation that corresponds to a highest elevation of the remaining portion 72. At the center of the opening 32, the remaining portion 72 can have a center elevation, wherein the sidewall elevation is higher than the center elevation. The surface 36 of the semiconductor layer 22 lies at a surface elevation. The sidewall elevation lies below the surface elevation. Each of the sidewall elevation, the center elevation, and the surface elevation can be measured from the primary surface 13 of the substrate 12.

Other shapes (not illustrated) of the remaining portion of the layer 42 may be formed within the opening 32. For example, in relatively wider openings (width of the openings is greater than double the thickness of the layer 42 as deposited), the remaining portion of the layer 42 may be substantially completely removed at the center of the wider openings, but the remaining portion of the layer 42 may include sidewall portions adjacent to the sidewalls 34 of the semiconductor layer. An electronic device can include a combination of shapes for the remaining portions of layer 42 that could vary with the width of the openings 32. Still other shapes can be used as long as the corner of the semiconductor layer 22 at the opening 32 and insulating layer 14 is substantially protected during a subsequent oxidation. The rest of the formation process uses the remaining portion 52 in FIG. 5 to simplify understanding of the process flow. After reading this specification, skilled artisans will appreciate that other shapes of the remaining portion, such as the remaining portion 62, remaining portion 72, etc. could be used in forming the electronic components within the electronic device.

A liner layer 82 can be formed along the exposed surfaces of the semiconductor layer 22, as illustrated in FIG. 8. The liner layer 82 can include one or more insulating films. In one embodiment, the liner layer 82 is formed by thermally oxidizing a portion of the semiconductor layer 22 using an oxygen-containing ambient (e.g., O₂, O₃, N₂O, another suitable oxidizing species, or any combination thereof). The oxidation-resistant layer 26 does not significantly oxidize during the thermal oxidation, and therefore can act as an oxidation mask during thermal oxidation. In one embodiment, the liner layer 82 has a thickness in a range of approximately 1 to approximately 20 nm, and in a more particular embodiment, in a range of approximately 7 to approximately 11 nm.

The thermal oxidation can cause corner rounding of semiconductor layer 22, adjacent to the pad layer 24, which results in rounded corners 84. The rounded corners 84 lie at or near the top of the sidewalls 34 of the semiconductor layer 22. The rounded corners 84 help to improve gate dielectric layer integrity. The remaining portion 52 slows or substantially prevents oxidation of the semiconductor layer 22 at the corners 86 adjacent to the insulating layer 14. Thus, the remaining portion 52 allows the liner layer 82 to be thicker than if liner layer 82 was formed when no remaining portion would be present adjacent to the bottom of the semiconductor layer 22.

In an alternative embodiment, the liner layer 82 can include one or more other insulating films that can be used in conjunction with or in place of the thermal oxide film. In one embodiment, a nitride film can be deposited using a conventional technique over the thermal oxide film. The nitride film can have a thickness in a range of approximately 1 to approximately 5 nm and may help to reduce erosion of the oxide film within the liner layer 82 during subsequent oxide etches, for example, when removing the pad layer 24, when forming and removing a sacrificial layer before forming a gate dielectric layer of the electronic device, etc.

In an alternative embodiment (not illustrated), the remaining portion 52 can optionally be removed at this point in the process. For example, if the remaining portion 52 includes a metallic element, the removal may reduce the likelihood of adverse consequences (due to the presence of the metallic element throughout the remainder of the process sequence).

An insulating layer 92 is formed and substantially fills the rest of the opening 32, as illustrated in FIG. 9. The insulating layer 92 can include an oxide, a nitride, an oxynitride, or a combination thereof and can be deposited using a conventional or proprietary technique. In one specific embodiment, the insulating layer 92 is formed by depositing an oxide film from tetraethylorthosilicate (TEOS) to a thickness that is at least one half the depth of the opening 32, and typically is as thick as the depth of the opening 32. The insulating layer 92 may have an undulating upper surface, a substantially flat upper surface, or something in-between.

Portions of the insulating layer 92 lying outside the opening 32 and overlying the oxidation-resistant layer 26 are removed to form a field isolation region 102, as illustrated in FIG. 10. The field isolation region 102 includes the remaining portion 52, the liner layer 82, and the insulating layer 92. In one embodiment, a conventional or proprietary chemical-mechanical polishing technique can be used, wherein the oxidation-resistant layer 26 can also act as a polish-stop layer. In another embodiment, the polishing operation could be continued until another layer underlying the oxidation-resistant layer 26 is reached.

In another embodiment, a conventional or proprietary etching process can be performed until the oxidation-resistant layer 26 is exposed, wherein the oxidation-resistant layer 26 can also act as an etch-stop layer. The etching may be performed as a timed etch or using endpoint detection (detecting the oxidation-resistant layer 26 has been reached) with a timed overetch. In one particular embodiment when the insulating layer 92 has an undulating surface, as deposited, a conventional or proprietary resist-etch-back process can be used. As the insulating layer 92 is etched, the etch chemistry may be changed before the oxidation-resistant layer 26 is reached to improve the etch selectivity (e.g., ratio of oxide etch rate to nitride etch rate is increased), and thus, decrease the likelihood of removing substantially all of the oxidation-resistant layer 26.

In FIG. 11, remaining portions of the oxidation-resistant layer 26 and the pad layer 24 are removed using a conventional or proprietary technique, if not previously removed when removing portions of the insulating layer 92 that were outside the opening 32. A wet etching technique, dry etching technique, or any combination thereof can be used to remove the oxidation-resistant layer 26, the pad layer 24, or both. In one embodiment, a dilute HF solution can be used to remove the pad layer 24. Relatively small amounts of the liner layer 82 and the insulating layer 92 may be removed if the pad layer 24, the liner layer 82, and the insulating layer 92 comprise substantially the same material (e.g., SiO₂). Such relatively small amounts typically do not significantly adversely affect the electronic device.

In another embodiment, not illustrated, a sacrificial oxide layer can be grown and removed at this point in the process. The sacrificial oxide layer can help to improve the surface quality of the semiconductor layer 22 before a gate dielectric layer or another layer is subsequently formed. The thickness of the sacrificial layer can be in a range of approximately 1 to approximately 20 nm. The sacrificial oxide layer may be formed in addition to or instead of the liner layer 82. If the liner layer 82 would not be formed, the sacrificial oxide layer can help to round the upper corners of the semiconductor layer 22 before a gate dielectric layer would be formed. The sacrificial oxide layer can be formed and removed using a conventional or proprietary process.

At this point in the process, electronic components, such as transistors 120, can be formed, as illustrated in FIG. 12. In one embodiment, the transistors 120 will have their active regions (i.e., source/drain and channel regions) formed within the semiconductor layer 22. The transistors 120 include an n-channel transistor, a p-channel transistor, or any combination thereof. Other electronic components, including a resistor, a capacitor, or any combination thereof, can be formed from portions of the semiconductor layer 22, if desired.

Optionally, a well dopant (not illustrated), a separate threshold adjust dopant, or other dopants may be introduced into portions of the semiconductor layer 22. An optional thermal cycle may be performed to activate the dopant(s). In another embodiment, the dopant(s) may be activated during subsequent processing.

A gate dielectric layer 122 is formed over the semiconductor layer 22, as illustrated in FIG. 12. The gate dielectric layer 122 can be formed using a conventional or proprietary growth technique, a deposition technique, or any combination thereof. The gate dielectric layer 122 can include one or more films of silicon dioxide, silicon nitride, silicon oxynitride, a metal-containing oxide, a metal-containing nitride, a metal-containing oxynitride, another high-k material, or any combination thereof. The gate dielectric layer 122 can have a thickness in a range of approximately 5 to approximately 50 nm in a substantially completed electronic device. In an alternative embodiment, the transistors 120 may have gate dielectric layers with different compositions, a different number of films within each gate dielectric layer, significantly different thicknesses, or any combination thereof.

Gate electrodes 124 are formed over the gate dielectric layer 122 using a conventional deposition and etch processing sequence. Each of the gate electrodes 124 can include one or more layers. The gate electrodes 124 can include a heavily doped amorphous silicon or polycrystalline silicon layer, a metal-containing layer, another suitable conductive layer, or any combination thereof. Each of the gate electrodes 124 has a thickness in a range of approximately 50 to approximately 300 nm. In an alternative embodiment, the transistors 120 may have gate electrodes with different compositions, a different number of films within each gate electrode, significantly different thicknesses, or any combination thereof.

The gate dielectric layer 122 and the gate electrodes 124 extend into and out of the drawing as illustrated in FIG. 12. The gate electrodes 124, such as the gate electrode 124 as illustrated in FIG. 13, may extend over the field isolation region 102 or a different field isolation region that is substantially similar to the field isolation region 102. Thus, each of the gate dielectric layer 122 and the gate electrodes 124 may lie adjacent to the surface 36 of the semiconductor layer 22 and adjacent to one or more of the rounded corners 84 of the semiconductor layer 22 (see FIG. 8).

An optional sidewall oxide layer (not illustrated) can be grown from exposed sides of the gate electrodes 124 to protect the gate electrodes 124 during subsequent processing. The thickness of the optional sidewall oxide layer can be in a range of approximately 2 to approximately 15 nm.

Sidewall spacers 126 and source/drain (“S/D”) regions 128 can be formed. In one embodiment, dopants for extension regions can be implanted after forming the gate electrodes 124 and before forming the sidewall spacers 126. The sidewall spacers 126 can be formed using conventional deposition techniques and may include an oxide layer, a nitride layer, or a combination thereof. Dopants for heavily doped regions can be implanted after forming the sidewall spacers 126. A thermal cycle can be performed to activate the dopants to form the S/D regions 128, which include extension and heavily doped regions. Portions of the semiconductor layer 22 lying under the gate electrodes 124 and between the S/D regions 128 are channel regions 129. At this point in the process, transistors 120 have been formed. Although not illustrated in FIG. 12, silicided regions can be formed from or over the gate electrodes 124, S/D regions 128, or any combination thereof. The silicided regions can be formed using a conventional or proprietary process.

Processing can be continued to form a substantially completed electronic device. One or more insulating layers, one or more conductive layers, and one or more passivating layers are formed using conventional techniques.

Embodiments as described herein can be used to provide benefits that overcome the problems with conventional structures and processes. The formation of the remaining portion 52, the remaining portion 62, the remaining portion 72, or any combination thereof before forming the rounded corners 84 are formed helps to reduce or substantially eliminate the bird's beak formation that would occur if the bottom corner of the semiconductor layer 22 would be exposed when forming the rounded corners 84. Also, the presence of the remaining portion 52, the remaining portion 62, the remaining portion 72, or any combination thereof can help to redirect the stress on the semiconductor layer 22, such that compressive stress on the semiconductor layer 22 is reduced. Electrical performance of transistors, particularly n-channel transistors, can be improved as compared to transistors formed adjacent to the field isolation region 18 in FIG. 1.

Many different aspects and embodiments are possible. Some of those aspects and embodiments are described below. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention.

In a first aspect, a process of forming the electronic device can include patterning the semiconductor layer to define an opening extending to an insulating layer, wherein the insulating layer lies between a substrate and the semiconductor layer. After patterning the semiconductor layer, the opening can have a bottom. The semiconductor layer can have a sidewall and a surface, wherein the surface is spaced apart from the insulating layer, and the sidewall extends from the surface towards the insulating layer. The process can also include forming a first layer over the substrate, wherein the first layer substantially fills the opening within the semiconductor layer. The process can further include removing a part of the first layer from within the opening. After removing the part of the first layer, a remaining portion of the first layer can lie within the opening and adjacent to the bottom and the sidewall, and the remaining portion of the first layer can be spaced apart from the surface.

In one embodiment of the first aspect, patterning the semiconductor layer can include patterning the semiconductor layer to define the opening extending to an insulating layer underlying the semiconductor layer, wherein the insulating layer overlies a substrate. In another embodiment, forming the first layer includes substantially completely filling the opening with the first layer. In a particular embodiment, patterning the semiconductor layer can include patterning the semiconductor layer to define the opening having a depth, and removing the part of the first layer can include removing the part of the first layer, wherein the remaining portion has a thickness at a center of the opening that is in a range of approximately 20% to approximately 80% of the depth of the opening.

In still another embodiment of the first aspect, forming the first layer can include forming the first layer using a PECVD technique. In yet another embodiment, forming the first layer can include forming the first layer using an inductively coupled plasma. In a further embodiment, removing the part of the first layer can include etching the first layer using a substantially isotropic etchant.

In still a further embodiment of the first aspect, removing the part of the first layer can be performed using a wet chemical etchant. In a particular embodiment, removing the part of the first layer can be performed using a partial drain refill tank. In another particular embodiment, forming the first layer can include depositing a nitride layer, and removing the part of the first layer can include exposing the nitride layer to H₃PO₄. In still another particular embodiment, removing the part of the first layer can include removing the part of the first layer, wherein, as seen from a cross-sectional view, the remaining portion has a dome shape. In another embodiment, removing the part of the first layer comprises removing the part of the first layer, wherein, as seen from a cross-sectional view, the remaining portion can have an extended portion. The extended portion can lies adjacent to the sidewall of the semiconductor layer and can have a highest elevation that lies above a center elevation of the remaining portion at a center of the opening and below a surface elevation of the surface of the semiconductor layer. Each of the highest elevation, the center elevation, and the surface elevation can be measured from a primary surface of the substrate.

In yet a further embodiment of the first aspect, the process can further include oxidizing the semiconductor layer. The semiconductor layer can include a first corner and a second corner the first corner is adjacent to the surface, and the second corner is adjacent to the insulating layer. The first corner can become rounded during oxidizing the semiconductor layer, and the second corner can substantially maintain its shape during oxidizing the semiconductor layer. In a particular embodiment, the process can further include depositing an oxide layer that substantially fills the rest of the opening, and polishing the oxide layer to remove a portion of the oxide layer lying outside the opening. In a more particular embodiment, the process can further include forming a patterned oxidation-resistant layer over the semiconductor layer before patterning the semiconductor layer, and removing the patterned oxidation-resistant layer after polishing the oxide layer. In another embodiment, the process can further include forming a gate dielectric layer adjacent to the surface and the first corner of the semiconductor layer. In a particular embodiment, the process can still further include forming a gate electrode. The gate dielectric layer can lie between the semiconductor layer and the gate electrode, and the gate electrode can lie adjacent to the surface and the first corner of the semiconductor layer.

In a second aspect, a process of forming an electronic device can include patterning a semiconductor layer to define an opening extending to an insulating layer underlying the semiconductor layer, wherein the insulating layer lies between a substrate and the semiconductor layer. After patterning the semiconductor layer. The opening has a bottom, and the semiconductor layer includes a sidewall, a surface, a first corner, and a second corner. The surface can be spaced apart from the bottom of the opening. The first corner can be adjacent to the surface and the sidewall, and the second corner can be adjacent to the sidewall and the insulating layer. The sidewall can extend from the surface towards the bottom of the opening.

The process of the second aspect can also include forming a first layer over the semiconductor layer and within the opening, and removing a part of the first layer from within the opening. After removing the part of the first layer, a remaining portion of the first layer may lie within the opening and adjacent to the bottom and the sidewall, the remaining portion of the first layer is spaced apart from the surface, and, as seen from a cross-sectional view, the remaining portion has a dome shape.

The process of the second aspect can further include oxidizing the semiconductor layer. The first corner can become rounded during oxidizing the semiconductor layer, and the second corner substantially may maintain its shape during oxidizing the semiconductor layer. The process can still further include depositing an oxide layer that substantially completely fills the rest of the opening, and polishing the oxide layer to remove a portion of the oxide layer lying outside the opening. The process can yet further include forming a gate dielectric layer adjacent to the surface and the first corner of the semiconductor layer, and forming a gate electrode. The gate dielectric layer can lie between the semiconductor layer and the gate electrode, and gate electrode may lie adjacent to the surface and the first corner of the semiconductor layer.

In a third aspect, an electronic device can include a substrate, an insulating layer, and a semiconductor layer, wherein the insulating layer lies between the substrate and the semiconductor layer. The semiconductor layer can have a sidewall and a surface, wherein the surface is spaced apart from the insulating layer, and the sidewall extends from the surface towards the insulating layer. The electronic device can also include a field isolation region overlying the insulating layer and lying adjacent to the sidewall of the semiconductor layer, wherein the field isolation region includes a first layer. The first layer can lie adjacent to the insulating layer and the sidewall, wherein the first layer is spaced apart from the surface. The first layer can have a sidewall elevation adjacent to the sidewall of the semiconductor layer and a center elevation at a center of the field isolation region. Each of the sidewall elevation and the center elevation can be measured in a direction perpendicular to the primary surface of the substrate. The sidewall elevation may be different from the center elevation.

In one embodiment of the third aspect, as seen from a cross-sectional view, the first layer has a dome shape. In another embodiment, the sidewall elevation can correspond to a highest elevation of the first layer, and the sidewall elevation may lie below a surface elevation of the surface of the semiconductor layer, wherein the surface elevation is measured from the primary surface of the substrate. In still another embodiment, the semiconductor layer can include a first corner and a second corner, wherein the first corner is adjacent to the surface, and the second corner is adjacent to the insulating layer, and the first corner is more rounded as compared to the second corner.

In a particular embodiment, the electronic device can further include an oxide material, wherein a combination of the oxide material and the first layer substantially fills the opening, and the first layer includes a nitride material. In a more particular embodiment, the electronic device can still further include a gate dielectric layer adjacent to the surface and the first corner of the semiconductor layer. The electronic device can yet further include a gate electrode, wherein the gate dielectric layer lies between the semiconductor layer and the gate electrode, and gate electrode lies adjacent to the surface and the first corner of the semiconductor layer.

Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.

One or more embodiments of the disclosure may be referred to herein, individually or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.

The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b) and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all of the features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

It is to be appreciated that certain features are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range.

The above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover any and all such modifications, enhancements, and other embodiments that fall within the scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description. 

1. A process of forming an electronic device comprising: providing a workpiece including a substrate, an insulating layer, and a semiconductor layer, wherein the insulating layer lies between the substrate and the semiconductor layer; patterning the semiconductor layer to define an opening extending to an insulating layer, wherein after patterning the semiconductor layer: the opening has a bottom, wherein the insulating layer lies along the bottom of the opening; the semiconductor layer has a sidewall and a surface; the surface is spaced apart from the insulating layer; and the sidewall extends from the surface towards the insulating layer; forming a first layer over the substrate, wherein the first layer substantially fills the opening within the semiconductor layer; removing a part of the first layer from within the opening, wherein after removing the part of the first layer: a remaining portion of the first layer lies within the opening and adjacent to the sidewall and lies along substantially all of the bottom of the trench; the remaining portion of the first layer is spaced apart from the surface; the remaining portion of the first layer has a first thickness at a center of the opening and a second thickness at a point closest to the sidewall, wherein as measured from the bottom of the opening, the first thickness is at least as thick as the second thickness: the remaining portion of the first layer fills approximately 20% to approximately 50% of the opening: and a portion of the sidewall is exposed within the opening; oxidizing the semiconductor layer while the remaining portion of the first layer lies within the opening, wherein: a first corner of the semiconductor layer immediately adjacent to the surface becomes rounded during oxidizing the semiconductor layer; a second corner of the semiconductor layer at an interface between the semiconductor layer and the insulating layer substantially maintains its shape during oxidizing the semiconductor layer; and the portion of the sidewall of the semiconductor layer is oxidized; depositing an insulating layer that substantially completely fills a rest of the opening after oxidizing the semiconductor layer; and removing a portion of the insulating layer lying outside the opening to form a field isolation region.
 2. The process of claim 1, further comprising: forming a gate dielectric layer adjacent to the surface and the first corner of the semiconductor layer, wherein forming the gate dielectric layer is performed after oxidizing the semiconductor layer; and forming a gate electrode, wherein: the gate dielectric layer lies between the semiconductor layer and the gate electrode; and the gate electrode extends over the field isolation region and lies adjacent to the surface and the first corner of the semiconductor layer.
 3. The process of claim 2, wherein after forming the gate electrode, the field isolation region substantially fills the opening in the semiconductor layer.
 4. The process of claim 1, wherein forming the first layer comprises depositing the first layer using a PECVD technique.
 5. The process of claim 1, wherein forming the first layer comprises depositing the first layer using an inductively coupled plasma.
 6. The process of claim 1, wherein removing the part of the first layer comprises etching the first layer using a substantially isotropic etchant.
 7. The process of claim 1, wherein removing the part of the first layer is performed using a wet chemical etchant.
 8. The process of claim 7, wherein: forming the first layer comprises depositing a nitride layer; and removing the part of the first layer comprises exposing the nitride layer to H₃PO₄.
 9. The process of claim 7, wherein removing the part of the first layer comprises removing the part of the first layer, wherein, as seen from a cross-sectional view, the remaining portion has a dome shape.
 10. The process of claim 1, wherein the remaining portion has a substantially uniform thickness, as measured from the bottom of the opening.
 11. The process of claim 1, wherein: depositing the insulating layer comprises depositing an oxide layer; and removing the portion of the insulating layer comprises polishing the oxide layer.
 12. The process of claim 1, wherein removing the portion of the insulating layer comprises polishing the insulating layer.
 13. The process of claim 1, wherein providing a workpiece comprises providing a workpiece including the semiconductor layer, wherein the semiconductor layer comprises germanium.
 14. A process of forming an electronic device comprising: patterning a semiconductor layer to define an opening extending to an insulating layer underlying the semiconductor layer, wherein the insulating layer between a substrate and the semiconductor layer, and after patterning the semiconductor layer: the opening has a bottom; the semiconductor layer includes a sidewall, a surface, a first corner, and a second corner; the surface is spaced apart from the bottom of the opening; the first corner is adjacent to the surface; the second corner is adjacent to the insulating layer; and the sidewall extends from the first corner to the second corner; forming a first layer over the semiconductor layer and within the opening; removing a part of the first layer from within the opening, wherein after removing the part of the first layer: a remaining portion of the first layer lies within the opening and adjacent to the bottom and the sidewall; the remaining portion of the first layer is spaced apart from the surface; and as seen from a cross-sectional view, the remaining portion has a dome shape; oxidizing the semiconductor layer, wherein: the first corner becomes rounded during oxidizing the semiconductor layer; and the second corner substantially maintains its shape during oxidizing the semiconductor layer; depositing an oxide layer that substantially completely fills a rest of the opening; polishing the oxide layer to remove a portion of the oxide layer lying outside the opening; forming a gate dielectric layer adjacent to the surface and the first corner of the semiconductor layer; and forming a gate electrode, wherein: the gate dielectric layer lies between the semiconductor layer and the gate electrode; and the gate electrode lies adjacent to the surface and the first corner of the semiconductor layer.
 15. The process of claim 14, wherein polishing the oxide layer forms a field isolation region within the opening in the semiconductor layer.
 16. The process of claim 15, wherein forming the gate electrode is performed such that the gate electrode extends over the field isolation region that substantially fills the opening in the semiconductor layer.
 17. The process of claim 16, wherein: patterning the semiconductor layer comprises patterning the semiconductor layer to define the opening having a depth; and removing the part of the first layer comprises removing the part of the first layer, wherein the remaining portion of the first layer has a thickness at a center of the opening that is in a range of approximately 20% to approximately 50% of the depth of the opening.
 18. The process of claim 16, wherein forming the first layer comprises depositing the first layer using an inductively coupled plasma.
 19. The process of claim 16, wherein removing the part of the first layer comprises etching the first layer using a substantially isotropic etchant.
 20. The process of claim 16, wherein removing the part of the first layer is performed using a wet chemical etchant. 